Control-Oriented Modelling and Predictive Quality Regulation for Large-Scale Additive Manufacturing

About the project

About the Project Large-scale additive manufacturing (AM) is a key enabler of sustainable, decentralised production for aerospace, renewable energy and infrastructure components. Autonomous and mobile AM platforms further extend this capability by replacing oversized gantries with coordinated motion. However, scaling AM to large volumes introduces severe challenges in process stability and quality regulation: geometric errors accumulate layer by layer due to thermal effects and deformation, while intra-layer deposition dynamics remain highly nonlinear and sensitive to force, material and environmental variability. Conventional feedback controllers and offline-calibrated parameters become ineffective under such varying operating conditions. This PhD will develop a multiscale, control-oriented learning framework that delivers stable, robust and physically interpretable quality regulation for large-scale AM. Two challenges will be addressed: (1) How to establish control-oriented data-driven model for nonlinear deposition dynamics; and (2) How to develop multiscale predictive quality regulation under uncertainty. The developed techniques will be validated through simulation and experimental studies on representative large-scale AM platforms available at UoM. Eligibility Applicants should have or expect to achieve at least a UK 2.1 honours degree in Mechanical and Mechatronic Engineering, Manufacturing Engineering, Computer Science or related disciplines. Experience in CAD/CAM, autonomous system and robotics development will be an advantage. Funding This 3.5-year PhD project is fully funded; students who are eligible to pay tuition fees at the Home rate are eligible to apply (more details can be found here ). The successful candidate will receive an annual tax-free stipend set at the UKRI rate (£21,805 for 2026/27) and tuition fees will be paid. We expect the stipend to increase each year. The start date is October 2026. The project is expected to start in September 2026, but applications will be accepted throughout the 2026/27 academic year, subject to availability. Before you apply We strongly recommend that you contact the supervisor for this project before you apply. Please include details of your current level of study, academic background and any relevant experience and include a paragraph about your motivation to study this PhD project. How to apply Apply online through our website: https://uom.link/pgr-apply-2425 When applying, you’ll need to specify the full name of this project, the name of your supervisor, if you already having funding or if you wish to be considered for available funding through the university, details of your previous study, and names and contact details of two referees. Your application will not be processed without all of the required documents submitted at the time of application, and we cannot accept responsibility for late or missed deadlines. Incomplete applications will not be considered. After you have applied you will be asked to upload the following supporting documents: Final Transcript and certificates of all awarded university level qualifications Interim Transcript of any university level qualifications in progress CV Supporting statement: A one or two page statement outlining your motivation to pursue postgraduate research and why you want to undertake postgraduate research at Manchester, any relevant research or work experience, the key findings of your previous research experience, and techniques and skills you’ve developed. (This is mandatory for all applicants and the application will be put on hold without it). Contact details for two referees (please make sure that the contact email you provide is an official university/work email address as we may need to verify the reference) English Language certificate (if applicable) If you have any questions about making an application, please contact our admissions team by emailing FSE.doctoralacademy.admissions@manchester.ac.uk . Equality, diversity and inclusion is fundamental to the success of The University of Manchester, and is at the heart of all of our activities. We know that diversity strengthens our research community, leading to enhanced research creativity, productivity and quality, and societal and economic impact. We actively encourage applicants from diverse career paths and backgrounds and from all sections of the community, regardless of age, disability, ethnicity, gender, gender expression, sexual orientation and transgender status. We also support applications from those returning from a career break or other roles. We consider offering flexible study arrangements (including part-time: 50%, 60% or 80%, depending on the project/funder).

Research areas